CHEMICAL ENERGY CONTROL MODULE™ System
User Manual
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Last Mod: 04 February 2016
Revision: 7.0
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Chemical Energy Control Module™ SMART ARC™
Chemical Energy Control Module™ UI Application
Chemical Energy Control Module™ Web Server
Network Setup & Connection Schemes
Administration
and Maintenance
Chemical Energy Control Module Website
The Chemical Energy Control Module™ is an integrated measurement, control and information system for Electric ARC Furnaces (EAF). It consists of a control module within the Smart Arc™ reading from PLC & other supported devices processing and sending data to a Windows Web Server for logging. A provided user interface application helps user to explode information with advanced and friendly controls as charts, navigation controls and more.
The difference from a conventional burner program based only on energy steps is that this new supervisory control module has several sub-modules with specific functions to determine the different requirements of the process for the operation practice optimization. The new control module is prepared to control systems with continuous material feed, like consteel furnaces, hot metal, DRI and HBI. In furnaces with continuous material feed, the system controls at the same time the temperature of the steel, the carbon content and the slag quality in order to achieve optimal results.
□ Advanced and user-friendly interface.
□ Chemical Energy Heat Sheet reports.
□ Continuous slag quality monitoring, temperature in the bath, carbon content and oxidation.
□ Continuous monitoring of chemical energy efficiency and burners operation.
The main design goal of the Chemical Energy Control Module™ System was to take advantage of the Smart Arc™ to incorporate a module dedicated to monitor and control chemical energy variables, giving user value information and a user-friendly interface that interacts with the Smart Arc™.
SmartARCTM is an EAF Artificial Intelligence based system using Fuzzy Logic algorithms instead of standard On-Off rules for building the knowledge behind the optimization criteria. But even more important, it is an on-line development platform to quickly implement any new emerging knowledge that can be used as new criteria for further optimization.
Inside the SmartARCTM all the logic for the optimization of Burners, Lances and Carbon Injection practices is prepared, and you will find several sub-modules:
1. Oxygen-Burner Profile
This profile adds flexibility to typical burner programs by allowing changing burner modes based on more information about the actual furnace conditions like heat stage detection, slag conditions, energy input, and the outputs of the Carbon-Oxygen Balance sub-module.
2. Carbon-Oxygen Balance
This sub-module estimates the oxidation of the steel bath. The estimation is then used to determine the best timing for start/stop of the oxygen lances or to change the oxygen and carbon flows. Its goal is to reduce delays caused by decarburization or oxidation requirements at the end of the heat, and optimize the use of oxygen and minimize the FeO content in the slag. When the carbon content sample is available, the module self-adjusts its parameters to improve its estimations.
The estimations are used to adjust the Oxygen-Burner Profile.
3. Carbon Injection
The carbon injection control works together with the Oxygen-Burner Profile and the Carbon-Oxygen Balance to optimize the carbon injection starting point, and the carbon flow based on the heat stage, energy consumption, slag conditions and the oxidation of the steel bath.
4. Slag Analysis
This logic based on slag chemical analysis calculates MgO saturation in the slag in order to recommend the required quantity of fluxes that should be added to the furnace in order to improve the slag foaming, arc stability and refractory protection.
5. Energy Balance
This sub-module provides a balance of the energy inputs and outputs, enhancing the temperature of the bath estimation. It also calculates the efficiency of the chemical energy usage while modifying the operation practices.
This User Interface application is designed to run in a Windows CPU to allow advanced graphics processing and interactive capabilities.
Chemical Energy Control Module™ UI has a large 1280x1024 pixel viewable area and is designed for touch screen monitors.
UI features include:
□ Customizable trends and graphs for heat with export option
□ Slag Analysis charts
□ Browseable heat sheets
□ Energy Balance charts
□ Multilanguage (upon request)
Chemical Energy Control Module™ Web server is a lightweight web server whose primary purpose is to work as an information repository for:
□ Heats data logging
□ Slag samples logging.
□ Configuration repository
□ Messages logging
□ UI application upgrades
□ Help pages database
It centralizes the information in a single place, and can be easily accessed using a standard web browser or via the embedded help viewer included with the UI application.

· Connect Smart Arc™ ETH0 to the internal hub.
· Connect WIN ETH0 to the internal hub.
· Connect the internal hub to the network.
· If PLC supports an Ethernet protocol (Modbus TCP, AB Ethernet, GE Ethernet) and it is not available through the main plant network, the Smart Arc™ ETH1 card can be configured as a node on the PLC network, given an IP address is assigned. Connection to the PLC might also be available through Modbus, Profibus, VMEBus or ControlNet.

· Connect Smart Arc™ ETH0 to plant network (assigned IP address)
· Connect Smart Arc™ ETH1 to either private AMI International local network or if PLC is in a separate ethernet network.
· Connect WIN ETH0 to plant network (assigned IP address)
· Connect WIN ETH1 to business network (assigned IP address)
· Connection to the PLC might also be available through Modbus, Profibus, VMEBus or ControlNet

· Connect Smart Arc™ ETH0 point to point with the PLC
· Connect Smart Arc™ ETH1 point to point with WIN ETH0
· Connect WIN ETH1 to the plant network (assigned IP Address)

· Install the prerequisites supplied with the application.

· Map the Win’s IP to the name burnerserver in the hosts file (normally located in C:\Windows\Sytem32\drivers\etc.
· Connect to http://burnerserver/
□ Click on the Download Regulator UI Application hyperlink

· Click on Install

· Launch the UI Application by double-clicking on the Burners icon located in the Windows Start Menu.
This section describes how to configure and operate the regulator using the UI Application.
Each section describes the screen, data and in some cases, the underlying process involved.
The customer can monitor with its own UI Application via Modbus.
For the following sections, we assume the following:
□ You have installed the Chemical Energy Control Module™ System (Hardware, software and UI Application)
□ You already know some concepts of Chemical
Energy like Carbon Estimation, Slag Analysis, etc.
□ You are familiar with the Microsoft’s Windows
operative system and terms like click, popup, drag & drop, maximize, etc.
The Chemical Energy Control Module consists of the regulation software running in one CPU and the UI Application, Web Server and other services in another CPU. They communicate via Ethernet and before connecting the UI Application to the regulator, both machines should be connected in the same LAN or via cross over.
The Chemical Energy Control Module™ UI Application was designed for the user to interact with either a touch screen or a regular keyboard and mouse.
The operation-related screens contain big buttons to be easily pressed using the fingers while the rest of the configuration screens may not have this feature.
Input Button
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The input buttons displays data that can be modified when clicking on it. This input buttons can be numerical, alphanumerical or predefined selections.
An input button can be enabled or disabled. Normally when these kinds of buttons are disabled, it indicates that your user level cannot modify its value or it is not available for certain configurations.
Displays
There are two types of displays; numerical and alphanumerical. Both are used to display live data or the configuration in use (some time this configuration is modified by other means).
They are typically preceded by a label of the variable they represent.
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Selection Buttons
As the name implies, this buttons are used to select an option or insert some configuration. There are four kinds of selection buttons:
· Primary Action: These buttons perform actions that normally have some effect on the model linked to them, the regulation process or some important action; these buttons are blue or red.
· Secondary Action: These buttons perform actions that normally change o display a view, normally an action that will not affect any model. They use the color light blue.
· Link: These are links to sections or screens. They use the color grey.
· Specials: Some button have special application in the UI Application like switching modes, sending end of heat signals, or they can be used as links and notify some condition, such as an alarm .
Additionally, some buttons may contain a small icon indicating its function.
Note
Depending on the situation or configuration, some buttons can be enabled, disabled, dimmed or hidden
Trend Graphs
It stores the information up to four hours depending of the samples per second configured (See User Preferences) or in other cases one sample per heat.
These graphs are placed in some of the configuration screens to provide feedback of the variables related to it. They are predefined variables and cannot be changed, only hide or displayed as needed using the checkboxes of the specific variable.

This kind of graphs can display up to four different variables sets with different scales/units each.

All the graphs can set specific scales for the displayed value independently or let the UI Application select the optimum scale by pressing the Auto button (See Scaling).
The variables are color-coded; the color in which the variable name is displayed is the color of the corresponding line in the graph. The phases use its standard color and only vary its tone when two variables contain the same phases.
Note
Some options may just be available in certain chart only.
Zoom:
To zoom-in a specific section of the trend, simply Marquee select the desired area. You may zoom several times until the desired detail level is reached. Some graphs have Vertical and Horizontal zoom buttons.
Note
Marquee selecting is the process of clicking-and-dragging the mouse pointer over a group of objects until a dotted line forms a box around it.
Right-click Menu
When you right-click on the graph, a context-sensitive menu will appear with some of the following option:
|
Option |
Action |
|
Display lines stair-step |
Shows the curve with the step lines instead of point to point lines |
|
Copy |
Sends a duplicate of the graph to the clipboard so you can use it in another location as an image |
|
Save Image As |
Stores the graph to an image file |
|
Page Setup |
Configures the printing options |
|
|
Prints the graph |
|
Show point values |
When this option is enabled, you can position the mouse over a trend point and a tooltip will show the values for that specific point |
|
Un-Zoom |
Reverts to the previous zoom level |
|
Undo All Zoom |
Disable all zooms and restores the original state |

Scaling Button
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All trends graphs displayed in the Data Logging & Monitoring screen can be scaled in two different ways:
· Auto: lets the UI Application adjust the best min and max values to display all the points in the graph
· Min & Max: the user sets the min and max values of the Y-axis scale
· Filter: when selected, the graph is displayed with a low pass filter. The only input needed is the value for “alpha”
· More Options: open a dialog with extended options like limits, units, format or show and hide the axis.

Help Button
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To access the help archives every screen contains a help button that will display a pop up screen with the specific help of the screen.
To access other screen help from an already opened window, click on the “Go Home” button and navigation map will appear.

Detach Button
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This button will detach the current screen to make two separate screens from the same session. This becomes helpful in two monitors setups, for example if you want to configure some parameters and see the trends at the same time.
The detached screen is always displayed on top of the other.
Notifications
Balloon
When a UI Application reads from a Modbus master service in the Windows machine call Data Server and sends a request to the web server, the UI Application displays connection status in its upper right corner.

Asynchronous
Process Status
The third led below the line brinks when at least one long process is running in the server. Click this led to show a dialog with the detail of all running process.

A running process may be cancel by click on the cancel button. The cancelation may not take effect immediately.
Screen Navigation
The screen navigation buttons let user move faster to the last visited screen (left row button) or go back to the next screen (right button).

Access Level
There are two access levels and does are shown in the above images. From left to right:
General Access. This is the initial access level, it allows the user to see and manipulate all Operation screens, use Analysis Profile screen and see (not change) some Configuration screens.
Admin Access. This level allows see and manipulate all screens that General Access does but also change Configurations and perform upgrades.
To go back in the access level just click the lock button again.
Keypad
Numerical values are entered using a keypad. The key pad was designed for touch screen usage, as well as the regular keyboard.
There are two types of keypads; one is for entering base 10 numbers, and the other for base 16 numbers (i.e. hardware addresses).
The keypad has a minimum and maximum values that can be entered for that particular variable, those values are displayed in the “Min:” and “Max:” labels. The same is for values that allow negatives or decimals, enabling or disabling the respective key button.
The display shows the actual value, and when a new value is entered, the old one is overwritten. If you just want to change the least significative digits without losing all the number, use the “<-” button to erase one by one until the desired one.

Keyboard
Like the keypad, the keyboard was designed to enter alphanumerical values in a touch screen and with a regular keyboard. The letters are arranged like in a regular QWERTY keyboard, and only some symbols were included for convenience, if additional symbols are needed those can be entered using the conventional keyboard (Some restrictions apply).
The display shows the actual value as in the keypad, but a difference is that when a new value is entered, it does not overwrite the previous; it is appended at the end of this.
· Backspace: erases the last character one by one.
· Clear: erases the entire input.
· Caps Lock: same as in a regular keyboard, but only affects the characters of the keyboard on screen.
· Shift: capitalize only the next character or selects the alternate characters.
Note
The text is masked with * when entering passwords.

Curve Preferences
Editor
Many graphs let users change curve preferences such as line color, symbol type or size. In cases, a square at the right of the variable’s name is shown.

Just click the preview square to access the Preferences dialog.

Log On Dialog
At the application startup a Log on dialog is show, the only thing you need to enter is the Windows machine’s IP address, where Chemical Energy Control™ services are running.

If the Show Connection Setting checkbox is unchecked, then the log on dialog will not be show the next time the application runs and will try to connect to the last succeeded IP address automatically.
Variable Selector
A
stander variable selector dialog is use in all the application. The design let
you quickly locate a variable by browsing it in a group (left list) or by type
the name or part of it in the search text box at the top.
Burners
variables are a special case, this variables, because
the large number of variables related to the burners; variables are group by
Variable and Type.

Menu
The Menu button located at the top right of the screen will allow you to go not only the operation screens but also to analysis and configuration.

Although UI Application does not need a special configuration to work, it is convenient that Burners and Scraps been enable and named.
By default this screen does not let user make any modification, to change configuration you need to enter a master password to get the right access level, just click the Lock button next to the menu.
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Once you have entered the master password correctly, the Scraps and Burners taps will be editable.
If user modify any field the modified control will be highlight and Save and Restore buttons will be enabled, the status will change to Modified.

The buttons action is:
·
Save:
Saves the on screen modifications. Sends model to the
Web Server.
·
Restore: Revert
changes before any save action.
·
Reset: Reset the model to default values.
For Burners and Scraps the configurable fields are:
· Label: The user defined name for scrap or burner (depending on Smart Arc™ configuration)
· Enable: Indicate if the scrap or burner will be show in operation screens.

The Operation Costs tab
allows you set a factor in order to calculate the cost of the shown variables
in the following image. The resultant cost may be seen at the Cost’s fields.
The calculated cost for a heat may be seen at the Performance screen.

The Furnace Panels tab let
you specify the number of panels of each furnace location; if your furnace
don’t has all available locations, just unchek the desired location. Once set
the number of panels for a location, you can give a name for each panel, is up
to you identify each panel.

System Maintenance
This screen configures the general settings of the Burners System.

Base Data Directory: Directory in the computer to save the logs.
Start Data Time: Start date of the system reading.
Show DRI Weight: In case your plant uses DRI you can customize your HMI to show the DRI Weight in the Furnace Overview.
Hide HMI on Shadow mode: The HMI monitors the current shell shadow mode and hides it if activated.
In
this screen user has the ability to change the default Unit of Measurement
(UOM) among most common units and not only that, Min, Max Step, Format and Limits; LEI for bottom and LES for top. This configuration
allows the correct display in charts and screen display controls.
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Change the default UOM for many or all variables may deplete performance. This is because UOM conversion is performed by the HMI at run time.
This configuration can be retrieved and stored from and to a Web Server, with the porpoise to be available any user. To do this Use the buttons ‘Save System’ and ‘Load System’ in this way configuration will be stored and retrieved from the Web Server. To use the System default click on ‘System Default’ button.
Note
After any change saved, application will automatically reset.
It is also
possible to see Modbus raw values doing click on
. It will show a table with the Modbus
Address, Path and Value among other properties.

Note
For heats variables (dot per heat); the units column is not available.
It might desire to have some calculated variables; well that is possible in this screen.

Let suppose you want to get the Total O2 Flow, to add this new variable just click on New in the Calculated Input Variables (left green list) and enter the expression:
[B1MainO2Flow]+[B2MainO2Flow]+[B3MainO2Flow]+[B1SHROUDFlow]+[B2SHROUDFlow]+[B3SHROUDFlow]
Note
It is possible to drag and drop variables from the available variables list (left for Input and right for Output). If the variables names are typed, they must be wrapped between brackets.
Note
For more information about allowed math functions please refer to http://www.sqlite.org/lang_corefunc.html.
By default all input variables are also listed as output variables, if a calculated variable is just a middle variable and you don’t want to throw it as output variable just select None in the Aggregation property in the Input variables.
Output variables might be grouped by:
· Avg
· Count
· Min
· Max
· Sum
The resultant value is attached to the heat report and might be available in the Heat Performance chart.
There might be some cases where you need to
calculate a new variable even after output variables have been grouped by heat;
for those cases, you can define a new Calculated Output Variables by defining
an expression build with any output variables.
Usage
To edit or remove a calculated variable, do a double click on it, the variable name, expression and aggregation (if case) will be display in the Variable Property section.
After changes were made, just click save/remove. Observe that the background color change depending on la source of the variable is been edited.
It’s easy locate a variable in any list, just tape the name or part of it in the search text box and the matching variables will be display.

In some cases you might want to roll back to the saved configuration, to do this click Reload Saved button. To start a new configuration with all available variables press Reset.
Once the configuration is ready, you can check the resultant XML using the Preview button. Dialog like this will be open.
Finally to save the configuration back to the server press Save Changes.
Note
A
basic validation is preformed when configuration is saved, however errors on
the configuration might affect the proper functioning. See diagnostics after any
change.
Note
Please consider that calculated variables are processed in the server side and it is a heavy load process, so the changes might not be visible immediately.
Note
Its highly recommended validate the changes by clicking the Validate button before save the configuration.
This section contains the operation and monitoring screens accessible to the operators. These screens contain common operation controls as well as diagnostics views.
This screen shows a general overview and configuration of the actual operation conditions. In other words, this is the summary of all application screens with the most important indicators; which are useful to the operators. It is also possible to navigate through heats in the past.

The
top timeline control let you select the Actual Heat or a past heat. When you
select a past heat all display values will change to the last value of the
selected heat, also the bottom chart loads the values of that heat. For a past
heat the shown value will turn fore color to gray to let you know the value is
not a real time value but is the last value of that heat.
Note
that, to remove a pencil
from chart you need to move the mouse over the pencil and a close button will
apear at the corner and to change pencil’s settings do a double click on the
variables’ name.
Heat Status
In
this section the actual heat status in presented.
|
Parameter |
Concept |
|
Heat Number |
The identifier of the current heat. |
|
Charge |
The actual charge. |
|
Power On |
Total time the furnace has being On in the current heat. |
|
Power Off |
Total time the furnace has being Off in the current heat. |
|
Heat MWh |
The MWh of the current heat. |
|
kWh/Ton |
The kWh per charged ton of material of the current heat. |
|
I2H |
Electrode Consumption Index. |
|
Avg SF |
Average Arc Stability Index. |
Carbon Estimation
In this section the estimation of the actual temperature, bath oxidation and carbon is presented, also the accuracy of the estimation (the labels turn to red for bad, yellow for medium and green for good). The following illustrations are just a sample of the color changes.

|
Parameter |
Concept |
|
Real Temperature |
Last temperature sample taken in the current heat. |
|
Real PPM |
Last PPM sample taken in the current heat. |
|
Real Carbon |
Last carbon sample taken in the current heat. |
|
Estimated Temperature |
Current estimation of the temperature in the actual heat. |
|
Estimated PPM |
Current estimation of the PPM in the actual heat. |
|
Estimated Carbon |
Current estimation of the Carbon in the actual heat. |
MgO Saturation
The graph represents the Isothermal Solubility Diagram (ISD), which is used to control the MgO Saturation of the slag. The saturation zone is the one with the “MW+L” label, to have a very good foaming and reduce refractory wear is recommended to work within the yellow zone of the chart below (around 1% of MgO super saturation). If we are working below this zone (in the blue zone) the slag will be very liquid and the foaming will not be very good, the same happens if we are working above this zone because the slag becomes very stiff.


Slag Analysis
The slag composition presented in this screen is estimated for the actual heat, but if the user selects slag performance it will show the composition of the sample of the heat selected.
|
Parameter |
Concept |
|
Temperature |
Estimated temperature of the current heat, or temperature of the slag sample. |
|
MgO Sat |
MgO Stauration. |
|
MgO SatDiff |
Difference from the MgO Saturation calculated and the MgO estimated of the current heat or from the slag sample. |
|
B3 Ratio |
Relation CaO/( Al2O3,+SiO2+ TiO2) |
|
Slag Quantity |
Estimated quantity of slag in the actual heat. |
|
Slag Energy |
Estimated energy absorbed by the actual slag quantity in kWh per ton of steel. |
|
Acids |
Quantity of Al2O3, SiO2 and TiO2 in the actual heat. |
|
FeO + MnO |
Target sum of percentage of FeO and MnO in the slag. |
|
MgO SupSat |
Target of MgO super saturation, if for example the super saturation target is 1%, the MgO percentage in the slag will be 1% above the current saturation. |
Trends
A trends chart is presented at the bottom of the screen; all heat variables are available for selection. The chart may also be changed to Scatter or Histogram.

This screen is useful to visualize the actual operation of the burners, the profiles from the Chemical Energy Control Module are more flexible than a typical burner programs, allowing changing burner modes based on information about the actual furnace conditions like heat stage detection, slag conditions, energy input, and the outputs of the Carbon-Oxygen Balance sub-module.

Available Burners
In this section the user is capable to decide which burners want to visualize in the graphs below.
Burner Variables
In this section, the user is capable to decide which variables want to be displayed in the graphs, per every burner.
|
Parameter |
Concept |
|
Set Point |
Reference that the SmartArc is sending to the burner, for oxygen, gas, carbon and lime. |
|
Flow |
Actual flow in the burner, for oxygen, gas, carbon and lime. |
|
Consumption |
Actual consumption in the burner, for oxygen, gas, carbon and lime. |
|
FreeO2 |
Is the freeO2 calculated for every burner. For more information see Carbon Estimation section. |
|
Gas MWh |
Actual MWh delivered for every burner, based on gas consumption. |
Heat Variables
In this section, the user is capable to decide which variables from the heat want to be displayed.
|
Parameter |
Concept |
|
S.F. Avg |
The Stability Factor of the current heat |
|
kWh/Ton |
Electrical energy input per every ton of charged material of the current heat. |
|
MWh |
Electrical energy input in MWh of the current heat. |
It is also possible to navigate among heats by using the navigation controls at the top of the screen.
This module estimates the oxidation of the steel bath. The estimation is then used to determine the best timing for start/stop of the oxygen lances or to change the oxygen and carbon flows. Its goal is to reduce delays caused by decarburization or oxidation requirements at the end of the heat, and optimize the use of oxygen and minimize the FeO content in the slag. When the carbon content sample is available, the module self-adjusts its parameters to improve its estimations.

Scrap Mix
|
Parameter |
Concept |
|
Total Weight |
Represent the total charged materials in the furnace in tons. |
|
Type |
Identifies the materials charged. |
|
Weight |
Tons of material. |
|
% |
Percentage from the total charged |

Composition
Helps to identify the quantity of materials (silica, manganese and carbon), which demand oxygen, and came with the scrap mix. Also the charge density is presented.

Fuels

|
Parameter |
Concept |
|
Scrap Si |
Represents the theoretical demand of oxygen from silica in the scrap. |
|
Scrap Mn |
Represents the theoretical demand of oxygen from manganese in the scrap. |
|
Scrap C |
Represents the theoretical demand of oxygen from carbon in the scrap. |
|
Charge C |
Represents the theoretical demand of oxygen from carbon charged in the bucket. |
|
Top Feed C |
Represents the theoretical demand of oxygen from carbon charged from the roof. |
|
C injected |
Represents the theoretical demand of oxygen from carbon of the injectors. |
|
Gas Injected |
Represents the theoretical demand of oxygen from gas of the burners. |
|
Total |
Total oxygen demand from fuels. |
Free O¿

|
Parameter |
Concept |
|
Total O2 Injected |
Total oxygen injected in scf per charged ton of material. |
|
Total O2 Required |
Total oxygen demand from fuels in scf per charged ton of material. |
|
Free O2/Ton |
Total O2 Required - Total O2 Injected |
Estimation
This part of the screen helps to visualize how the
estimation of PPM, Carbon in the Bath and Steel Temperature is working.
User can filter the number of samples by entering a value largest than zero.
It is normal that first heat estimation could be some loose, in this cases user may want filter those estimations, in this case checking Include First Sample will dismiss all first heat estimations.
The next graph represents a trending of the last samples, the real and estimated values.

The next graph represents a scatter of the last samples, in the y-axis is the PPM, Carbon or Temperature estimation and in the x-axis the real value, helping to visualize the accuracy of the estimation.

This sub-module provides a balance of the energy inputs and outputs which helps to visualize the energy distribution, and where does the energy goes when a change on the burners profile is done. This sub-module is responsible for the temperature estimation. It also helps to measure the efficiency of the chemical energy usage while modifying the operation practices. The system also keeps a history of the energy input and output distribution for comparison through time.
The screen is subdivided in two sections one called “Energy In & Out” and the other “Energy Charts”.

Energy In
|
Parameter |
Concept |
|
Electrical |
Total electrical energy in kWh per steel ton. |
|
Chemical |
Total chemical energy in kWh per steel ton. |
|
Mn |
Chemical energy from manganese oxidation. |
|
Si |
Chemical energy from silica oxidation. |
|
Fe |
Chemical energy from iron oxidation. |
|
Al |
Chemical energy from aluminum oxidation. |
|
C Charge |
Chemical energy from the oxidation of carbon charged in the bucket. |
|
C Top Feed |
Chemical energy from the oxidation of top feed carbon. |
|
C Injected |
Chemical energy from the oxidation of carbon injected. |
|
C Electrodes |
Chemical energy from the oxidation of electrodes carbon. |
|
Gas |
Chemical energy from the oxidation of gas injected. |
|
Unaccountable |
Energy in, which could not be accounted but is used to adjust the energy balance. |

|
Parameter |
Concept |
|
Metal |
Energy absorbed by the metal in kWh per ton of metal. |
|
Slag |
Energy absorbed by the slag in kWh per ton of steel. |
|
Off Gas |
Energy losses by the off gas in kWh per ton of steel. |
|
WC Panels |
Energy losses by the water cooled panels in kWh per ton of steel. |
|
Side Walls |
Energy losses by water of the side walls panels in kWh per ton of steel. |
|
Roof |
Energy losses by water of the roof panels in kWh per ton of steel. |
|
Duct |
Energy losses by water of the duct panels in kWh per ton of steel. |
|
Unaccountable |
Energy out, which could not be accounted but is used to adjust the energy balance. |
|
Efficiency |
Ratio between energy in and energy that goes to the metal. |
Energy Out

Energy Charts
In this screen user can query today’s data, week to date, month to date or even year to date, or can select a custom date range.

Trends
This chart shows the trends of the different sources of energy contribution and losses, helping to trace the effect of any modification on the operational practices on the energy distribution.
Gas Efficiency
This chart shows the effect that gas injected has on the total electrical energy consumption per heat, the effect of the gas could be seen in different stages of the heat (preheating, melting, melting + preheating and total gas).
For the slag analysis it is required to have a slag analyzer available. This screen based on slag chemical analysis recommends quantity of fluxes that should be added to the furnace in order to reach an optimum MgO saturation level in the slag, improving the slag foaming, arc stability and refractory protection. The system also generates comprehensive graphics of the history data, allowing users to decide what is the best target for the slag basicity. These estimations are critical to achieve a high performance operation, minimizing FeO content in the slag and the losses in energy required to create the slag.
The screen is composed of two sections, Slag Analysis and Slag Performance, the first one is based on information of the heat and estimations, the second one is for heats where a slag sample was took.

MgO Saturation
The graph represents the Isothermal Solubility Diagram (ISD), which is used to control the MgO Saturation of the slag. The saturation zone is the one with the “MW+L” label, to have a very good foaming and reduce refractory wear is recommended to work within the yellow zone of the chart below (around 1% of MgO super saturation). If we are working below this zone (in the blue zone) the slag will be very liquid and the foaming will not be very good, the same happens if we are working above this zone because the slag becomes very stiff.

The slag composition presented in this screen estimate for the actual heat, but if the user selects slag performance it will show the composition of the sample of the heat selected.
|
Parameter |
Concept |
|
Temperature |
Estimated temperature of the current heat, or temperature of the slag sample. |
|
MgO Sat |
MgO Stauration. |
|
MgO SatDiff |
Difference from the MgO Saturation calculated and the MgO estimated of the current heat or from the slag sample. |
|
Iron Losses |
|
Heat Trends
This chart shows the trending of some of the indicators of the last heats (one point per heat), it helps to visualize how B3 ratio, %FeO in slag, kWh/Ton, MgO Diff has variated in a certain period of time.
|
Parameter |
Concept |
|
Charge Number |
Current charge number. |
|
Lime Charged |
Total lime charged in the actual heat. |
|
Dolo Charged |
Total dolomite lime charged in the actual heat. |
|
Acids |
Quantity of Al2O3, SiO2 and TiO2 in the actual heat. |
|
B3 Ratio |
Relation CaO/( Al2O3,+SiO2+ TiO2) |
|
Slag Quantity |
Estimated quantity of slag in the actual heat. |
|
Slag Energy |
Estimated energy absorbed by the actual slag quantity in kWh per ton of steel. |
Slag Fluxes

Targets
|
Parameter |
Concept |
|
B3 Target |
Target basicity for the current heat. |
|
FeO + MnO |
Target sum of percentage of FeO and MnO in the slag. |
|
MgO SupSat |
Target of MgO super saturation, if for example the super saturation target is 1%, the MgO percentage in the slag will be 1% above the current saturation. |

|
Parameter |
Concept |
|
Lime |
Recommended quantity of lime in lb for the current heat. |
|
Dolo |
Recommended quantity of Dolomite Lime in lb for the current heat. |
|
Slag Quantity |
Quantity of slag that will be produced with the current recommendation of fluxes. |
|
Slag Energy |
Energy absorbed by the slag in kWh per ton of steel. |
Recommended

Slag Performance
The Slag Performance chart is created from those heats where a slag sample was took. To create this charts the X axis is created by ranges (bins) of MgO Saturation or B3 Ration values of slag samples. The retrieved data may be filtered a Step, Min and Max, or any other criteria. To see original data chart click on Source Chart button.

This screen is used to monitor the current heat, and view the history of the most important indicators of past heats.

Heat Trends
This chart shows the trending of some of the indicators of the last heats (one point per heat), for example it helps to visualize how energy, power on time, and the consumption of carbon, gas and oxygen has varied in a certain period of time. It is also possible to define your own set of variables, just select “Custom” at the top left combo box, select variables and give them a name and save it; the new pencils set will be show and added to the combo box.
It is also possible to open in a new window the Heat Trends chart, consider that the selected span time of data is shared between dechated and original chart, but not selected pencils.
Detach
chart
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Heat Status

|
Parameter |
Concept |
|
Master Program |
The actual Master Program |
|
Charge |
The actual charge. |
|
Power On |
Total time the furnace has being On in the current heat. |
|
Power Off |
Total time the furnace has being Off in the current heat. |
|
Heat MWh |
The MWh of the current heat. |
|
I2H |
Electrode Consumption Index. |
|
Heat Avg MW |
The average power input. |
|
Heat kWh per Ton |
The kWh per charged ton of material of the current heat. |
|
Avg SF |
Average Arc Stability Index. |
|
Free O2/ton |
Total O2/ton - Total O2 Req/ton |
Energy

|
Parameter |
Concept |
|
In |
Total energy feed into the furnace in kWh per steel ton, electrical plus chemical. |
|
Electrical |
Total electrical energy in kWh per steel ton. |
|
Chemical |
Total chemical energy in kWh per steel ton. |
|
Unaccountable |
Energy in, which could not be accounted but is used to adjust the energy balance. |
|
Metal |
Energy absorbed by the metal in kWh per ton of metal. |
|
Slag |
Energy absorbed by the slag in kWh per ton of steel. |
|
Off Gas |
Energy losses by the off gas in kWh per ton of steel. |
|
WC Panels |
Energy losses by the water cooled panels in kWh per ton of steel. |
|
Unaccountable |
Energy out, which could not be accounted but is used to adjust the energy balance. |
Heat Composition
|
Parameter |
Concept |
|
Heat Weight |
Represent the total charged materials in the furnace in tons and percentage. |
|
DRI Weight |
The total charged DRI in the furnace as well as the percentage. |
|
Scrap |
Current scrap mix percentage of silica, manganese and carbon. |
Operation Costs

|
Parameter |
Concept |
|
MWh |
The consumption and cost of MWh in the heat. |
|
O2 |
The total consumption and cost of O2 in the heat. |
|
Gas |
The total consumption and cost of Gas in the heat. |
|
Carbon |
The total consumption and cost of`Carbon in the heat. |
|
Lime |
The total consumption and cost of Lime in the heat. |
|
Dolo |
The total consumption and cost of Dolo in the heat. |
Carbon Estimation

|
Parameter |
Concept |
|
Sample Temperature |
Last temperature sample taken in the current heat. |
|
Sample PPM |
Last PPM sample taken in the current heat. |
|
Sample Carbon |
Last carbon sample taken in the current heat. |
|
Estimated Temperature |
Current estimation of the temperature in the actual heat. |
|
Estimated PPM |
Current estimation of the PPM in the actual heat. |
|
Estimated Carbon |
Current estimation of the Carbon in the actual heat. |
The Timeline button let user search a heat quickly. It shows a one-week timeline. The up-right calendar let user move among weeks, months and event years faster. The up and down blue rows make a one-week jump forward or backward. The up and down green rows make a one-day jump. Just click the heat for selection.

If user needs to see heat data in a chart the Heat Chart button will show the following chart dialog.

General heat information is show at the top of the dialog. There are tree chart types.
· Trend: Use only a time X axis. By default, curves are show as lines.
· Scatter: Let user choose any X axis available in the Pencil Set panel. By default, curves are show as symbols.
· Histogram: The X axis is automatically measured and divided in 40 bins. By default, curves are show as line and symbol.
To add variables to the graph just click in the Plus button, a Variable selector dialog shows all available variables grouped by object.

Variables can be grouped Logically, for example if you want to chart all burners Gas Consumption it may be a lot of work to select each burner Gas Consumption instead you just select Gas Consumption in the Logical grouped list and all burners variables will be added to the chart with only one Y axis and scale.
The right-top row button, expand the dialog to show a complete list of available variables. It is also possible to search a particular variable by typing part of its name in the Search text box.
Once you have a chart with all your preferences such as variables, colors, chart type and scales; it is possible to save them, just click in the left dock Options label to show Load and Save options.

If you need to filter charts data go to Options panel and mark the Filtering options checkbox. A “Filter By” panel will be show at the bottom of the chart, press plus button to add a new condition. For example to define a filter that show samples with MWh greater or equal than 10 MWh.

You can add as much conditions as you need, Condition may be connected by OR or AND operator in order to create complex expressions; there are also open and close parenthesis to create even more complex expression, just click the button “(“ to rotate to other symbol. To delete a condition just click the minus button at the right.

If the created expression has a syntaxes error, the expression string at the bottom will show you the error.
This screen shows notification of the activity of the system as well as global system malfunction and critical condition.
The Alarms button flashes when a new alarm is raise, the blinking color depends on the Priority of the alarm. To stop button flashing, just click the Alarm button.
Press “shift” key + “Alarms” button to show the screen in full screen showing the inner data column.
In this window, you can sort by any of the columns and scroll thru all the messages.
You can export these messages to an excel file with the “Export” button.

There is a hidden column called inner data, you can bring this column to view by clicking on any message while holding down the shift key. Alternately place the mouse pointer over the date of the desired message and a tool tip will display the inner data info if exists in that particular message.
This screen not only shows automatic abnormal vapors detections but also let you report new events and set them fix.

You can use the Heat Navigator at the top of the screen just like other screens to locate a desired heat. This control has also a backward and forward navigation buttons for Events in order to move through them. When a heat has an Abnormal Vapor Event (AVE) is shown with a specific color depending on its status; the following are the available status colors.
Event Detected
First Sight, Seen and Fixed (Not detected)
First Sight, Seen and Fixed (Detected)
Fixed
Heat without event
By holding the mouse over a heat, a tooltip will show the basic information of the heat and event.
There are two ways to create an AVE record. Just locate the desired Heat and select one of the following options.
· First Sight - Most used in the Actual Heat when a abnormal vapor is sight for first time and was not fixed.
· Seen and Fixed – When an event has seen and fixed at the same heat.
Any of previous options will open a dialog where you can give more detail of the location of the abnormal vapor, just as shown in the following image.

Note
See Furnace Panels at Configuration section to configure number and label of the furnace panels.
To set an AVE as fixed, you need to locate the event using the Navigation control, once located and selected click the Fix button at the Event Detail panel, a dialog will open, showing the Heat where the AVE was created (not editable) and the Heat where it was fixed; it is also possible to change the details of the event.
To edit a AVE just click the Edit Event button at the Event Detail panel, a dialog will open showing the detail of the event. It is possible to change the Heat Number where the event was created.

At the bottom of the screen, you can find a trend chart of the H2O (%), H2O Estimation (%) and the Abnormal Vapor Alarm signal, this trend will help you see the level of the water and if there is some lost. Finally, there is a count of events for Day, Week and Month.
To export the report of heats between two dates and its abnormal vapor events, click the Export Events button and specify the date range; a CSV file will be generate with the historic information.
This section contains the analysis screens, where users may join data and customize charts for study.
This screen allow user to define one or more charts from up to tree types of data sources; charts may be arrange in a grid to show one, two or four charts at the time. A set of data sources and charts is known as an Analysis Profile.

The main controls allow you to Create new, Open, Save (Web Server by default) or Save As an Analysis Profile. The charts layout may be Single, Split or Four Charts view.

The Profile tab allows you
to set the profile name, just click on edit button at the right of the list,
set a description and view the selected data sources. If you want to remove a
data source just select it from the list and click on the trash button, if the
data source has charts bounded you will be cuestion about to remove the related
charts.
Tip
A double click on any Data Source listed will show up the Data Source Settings panel.
Data Sources
You may want to use data from the available sources.
· Heat Trends. One dot per heat.
· Heat Log. 2 seconds logs from a single heat.
· Rph/Rpd/Rpm. External data files.
Heat Trends
One dot per heat. This data source will get data from a range of dates. It may be Today, Year to Date, Month to Date, Week to Date or a Custom date range. You may also define the scale of available variables or define a filtering expression.
Heat Log

2 seconds logs from a single heat. This is like a heat chart, you can browse heats by the rows; left for previous heat and right for next heat. If you prefer you can use the time line browser to select a heat, just click the Timeline button. You may also define the scale of available variables or define a filtering expression.
Rph/Rpd/Rpm

External data files. Just click on the big open button at the left and select valid files; all selected files must have the same extension: rph, rpd or rpm; the available variables are taken form the first selected file. You may also define the scale of available variables or define a filtering expression. When rph files are selected you can browse among files using the arrow buttons; otherwise, for rpd or rpm all selected files are loaded at once in a single set of data.
It is also possible to see source data in a grid fashion view, just click in the Show Data button in any Data Source Setting panel. Please note that only selected variables will be loaded (data retrieved from source) and are the only shown in the grid; data might not be filtered here, but they can be selected and copied in the clipboard.

Chart Settings
All charts are available to select by click on the title bar or close them using the cross button. To set or change the title, just do a double click on the title bar. The following figure shows you all available options to customize a single chart.

The plus button allows you to add a variable, the clean button will remove all previously added variables. A set of variables can be saved and loaded using Load and Save buttons. The available chart types are: Trend, Scatter, Histogram, Distribution and XYColor. You could also export chart data and define scales, the defined scales at the chart level will overwrite the scales defined at the Data Source level.
For Regression lines click on More Options button; the following dialog will let you select the variable over which the regression will be calculated and the regression type.

The regression information
will be shown at the buttom of the chart.
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Sometimes is usefull to
have an statistic report of a variable; there are two ways to get this: by
ricgt click over the cuve of right click over the scale of the desired variable
and selecting the Curve Statistics option on the context menu; a dialog will be
open with the statistic information.

Special Charts
The Distribution chart is available only in the Analysis Profile screen, the X Axis variable is distributed among 50 bins in order to create the chart and presented as bars and additional variables are overlap as lines.

Multi-variable Distribution chart
This is a special option available only at any Analysis Profile Data Source options. What it does is to create groups depending on the different values of the Group By variable for each variable listed

The following image shows
two grouped variables for HeatMWh when ActualPwrLvl is 6 and 10.

Note
Any change in the Grouping options will cause to drop any created chart in the same Data Source. This is because data need to be re-grouped and series may not be the same.
This screen allows the user to perform an upgrade of the Chemical Energy Control Module (Windows machine).
Before you can try to upgrade system, you need to enable edition in the Configuration screen by clicking in the Lock button and type the master password.
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Once you have entered the master password correctly, the Upgrade tab will be show. Select the upgrade file using the select button, and press the upgrade button to start the process. The input only allows zip and tgz (*.tar.gz) files with valid data to be sent as upgrade.

Special consideration when upgrading the system:
1. This procedure should be done with the furnace OFF.
2. Some expected network disconnections will occur in the process, but if after a considerable amount of time there is no reconnection, a system reboot should be performed.
3. If the process was successful then the Chemical Energy Control Module system will restart with the upgraded software, if not the system may restart with the previous software.
4. After an upgrade it is recommended to restart the Windows machine to ensure a fresh installation is being run.
5. For any other issues not described here contact AMI-GE Tech Support.
This screen allows the user to change the User Interface language, set a heat number prefix and define the minimums number of digits when a heat number is display.

The Screen Settings section let you export the state of all screens (selected variables and its preferences for charts, etc) to a binary file. In the same way you can import a screen settings file to the application.

The main function of the website is to provide access to the Chemical Energy Control web services via a browser.
Download UI
Monitoring Application
Click the install button to download and install the latest UI Application. The page displays the name, version and publisher of the application.
This feature utilizes ClickOnce technology, and it is designed to work easily with Microsoft Internet Explorer.
Help Provider
Displays the same information found in the help screens of the UI Application,
Heat Sheets
Displays the stored heat sheets, by default the page shows today’s data.
Click on the link of the corresponding heat sheet to display its contest at the end of the page. The format is Heat Number @ date time.
Select a different date from the calendar to get older heat sheets.
· Check if Windows machine is reachable by name (burnerserver, see hosts file). It is possible that the Burners Data Server windows service been corrupted, in this case just restart the windows service in the Windows machine. Close and open the UI Monitoring application.